Energy absorbing wall assemblies and related methods

ABSTRACT

Energy absorbing wall assemblies, structures including energy absorbing wall assemblies, methods of making energy absorbing wall assemblies, and methods of utilizing energy absorbing wall assemblies are disclosed herein. In some embodiments, energy absorbing wall assemblies may include a first self-supporting wall structure, a second self-supporting wall structure, and an energy absorbing filler material positioned between the first self-supporting wall structure and the second self-supporting wall structure. In additional embodiments, methods of making an energy absorbing wall assembly may include assembling a first self-supporting wall structure, and assembling a second self-supporting wall structure defining a space between the first self-supporting wall structure and the second self-supporting wall structure. The methods may further include flowing an energy absorbing filler material into the space between the first self-supporting wall structure and the second self-supporting wall structure.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/303,917, filed Feb. 12, 2010, the disclosure ofwhich is hereby incorporated herein in its entirety by this reference.

BRIEF SUMMARY

In some embodiments, energy absorbing wall assemblies may include afirst self-supporting wall structure, a second self-supporting wallstructure, and an energy absorbing filler material positioned betweenthe first self-supporting wall structure and the second self-supportingwall structure.

In additional embodiments, methods of making an energy absorbing wallassembly may include assembling a first self-supporting wall structure,and assembling a second self-supporting wall structure defining a spacebetween the first self-supporting wall structure and the secondself-supporting wall structure. The methods may further include flowingan energy absorbing filler material into the space between the firstself-supporting wall structure and the second self-supporting wallstructure.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 shows an isometric view of a portion of an energy absorbing wallassembly, according to an embodiment of the present invention.

FIG. 2 shows an isometric view of a portion of an energy absorbing wallassembly, such as shown in FIG. 1, further including a permeable fence.

FIG. 3 shows a cross-sectional side view of a precursor assembly forforming a column and panel fence for an energy absorbing wall assembly,such as shown in FIGS. 1 and 2, the precursor assembly including afooting, elongated member and a retaining bracket.

FIG. 4 shows the precursor assembly of FIG. 3 further including a panelpositioned on the footing.

FIG. 5 shows the precursor assembly of FIG. 4 further including a firstcolumn face positioned against a side of the panel.

FIG. 6 shows the precursor assembly of FIG. 5 further including a secondcolumn face positioned against an opposing side of the panel.

FIG. 7 shows the precursor assembly of FIG. 6 further including across-piece positioned over the column faces and coupled to theelongated member.

FIG. 8 shows the precursor assembly of FIG. 7 wherein the cross-piece iscoupled to the column faces, and wherein the cross-piece and elongatedmember are put into tension to form a column.

FIG. 9 shows the column of FIG. 8 further including a cap positionedover the column faces and the cross-piece.

FIG. 10 shows an isometric view of a portion of a first column and panelfence and a second column and panel fence positioned for forming anenergy absorbing wall assembly as shown in FIG. 1.

FIG. 11 shows an isometric view of a portion of a first column and panelfence, a second column and panel fence, and a chain-link fencepositioned for forming an energy absorbing wall assembly as shown inFIG. 2.

FIG. 12 shows a cross-sectional view of a energy absorbing wallassembly, such as shown in FIG. 1, having an energy absorbing fillermaterial including used tires positioned between first and secondself-supporting wall structures.

DETAILED DESCRIPTION

In some embodiments, as shown in FIG. 1, an energy absorbing wallassembly 2 may include a first self-supporting wall structure 4, asecond self-supporting wall structure 6 and an energy absorbing fillermaterial 8 positioned therebetween. The second self-supporting wallstructure 6 may be positioned substantially parallel to the firstself-supporting wall structure 4 and the filler material 8 positionedtherebetween may substantially fill an entire space between the firstself-supporting wall structure 4 and the second self-supporting wallstructure 6.

Each self-supporting wall structure 4, 6 may be a free-standingstructure. Furthermore, each self-supporting wall structure 4, 6 may beformed by a wall structure that may be utilized on its own as afunctional wall. For example, each self-supporting wall structure 4, 6may be a column and panel fence, such as described in U.S. patentapplication Ser. No. 12/631,495, filed on Dec. 4, 2009, by the inventorof the present invention and incorporated herein in its entirety by thisreference. As the exterior of the energy absorbing wall assembly 2 maybe formed by the self-supporting wall structures 4, 6 and free-standingfencing may be utilized as the self-supporting wall structures 4, 6, theenergy absorbing wall assembly 2 may be aesthetically pleasing and may,thus, be configured with a selected surface finish pattern, texture,color, etc., to provide an appearance that is consistent with that ofthe surrounding community. In other words, at least one of the first andsecond self-supporting wall structures 4, 6 may be, or at least have theappearance of, a conventional fence. Furthermore, the first and secondself-supporting wall structures 4, 6 may provide an anti-spalling andanti-ricochet outer surface of the energy absorbing wall assembly 2.

Each self-supporting wall structure 4, 6 may comprise preformed concretepanels 10 positioned between and held upright by columns 12 anchored tothe ground, such as by a footing 14 (FIGS. 3-9), a foundation, oranother type of anchor. In some embodiments, the columns 12 of the firstself-supporting wall structure 4 may be aligned with columns 12 of thesecond self-supporting wall structure 6, as shown in FIG. 1. Inadditional embodiments, the columns 12 of the first self-supporting wallstructure 4 may be staggered relative to the columns 12 of the secondself-supporting wall structure 6, as shown in FIG. 2.

In some embodiments, the first and second self-supporting wallstructures 4, 6 may be substantially identical in construction andheight, such as shown in FIGS. 1 and 2. This may allow commoncomponents, materials, tools and construction methods to be used foreach self-supporting wall structure 4, 6. In additional embodiments, thefirst and second self-supporting wall structures 4, 6 may besignificantly different in one or more of construction, height, andother aspects (not shown). For example, the first self-supporting wallstructure 4 may comprise an outer wall of a building and the secondself-supporting wall structure 6 may be a fence spaced from the outerwall of the building (not shown). In some embodiments, a permeable fence16 may be positioned between the first and second self-supporting wallstructures 4, 6, such as shown in FIG. 2. Additionally, the permeablefence 16 may extend higher than the first and second self-supportingwall structures. For example, and as illustrated in FIG. 2, a chain-linkfence may be positioned between and extend above the first and secondself-supporting wall structures 4, 6. Additionally, the permeable fence16 may be positioned adjacent one of the first and secondself-supporting wall structures 4, 6. At least a portion of the energyabsorbing filler material 8 may be flowable, at least when initiallypositioned between the first and second self-supporting wall structures4, 6, and the flowable, energy absorbing filler material 8 may penetratethe permeable fence 16 and surround and substantially encapsulate thelower portion of the permeable fence 16.

The energy absorbing filler material 8 may comprise a material that isinitially flowable, to facilitate the positioning of the energyabsorbing filler material 8 between the first and second self-supportingwall structures 4, 6. After positioning between the first and secondself-supporting wall structures 4, 6 the energy absorbing fillermaterial 8 may exhibit energy absorbing properties. In some embodiments,the energy absorbing filler material may be a monolithic structure, suchas a monolithic collapsible material comprising a relatively brittlecellular matrix encapsulating relatively small, collapsible pockets,such as gas (e.g., air) pockets. For example, the energy absorbingfiller material 8 may be a cellular concrete. In some embodiments acellular concrete may be formed from hydraulic cement, water andpre-formed foam. In additional embodiments, other methods of entraininggas into uncured concrete may be utilized (e.g., gas producing chemicalreactants, aspirating nozzles, porous aggregate, aeration, etc.). Insome embodiments, a cellular concrete comprising about 40 percent air toabout 60 percent air may be utilized. For a non-limiting example, acellular concrete comprising about 50 percent air may be utilized. Theamount of air entrained in the cellular concrete may be varied accordingto the application that the energy absorbing wall assembly 2 is intendedand the configuration and intensity of any kinetic energy that theenergy absorbing wall assembly 2 is configured to absorb. In additionalembodiments, the energy absorbing filler material 8 may comprise aflowable particulate, such as one or more of sand, dirt, gravel, andother flowable particulates. The energy absorbing filler material 8 mayalso comprise additional material and structures. In some embodiments,the energy absorbing filler material 8 may comprise discrete energyabsorbing structures positioned between the wall structures that mayform cavities and voids that may be filled with the flowable material.For example, used tires 18 (FIG. 12) may be stacked between the firstand second self-supporting wall structures 4, 6. In view of this, theenergy absorbing filler material 8 may comprise a plurality of discreteenergy absorbing structures encapsulated in a monolithic energyabsorbing material.

In some embodiments, an energy absorbing wall assembly 2 may beassembled by first assembling first and second self-supporting wallstructures 4, 6 spaced apart and then filling the space between thefirst and second self-supporting wall structures 4, 6 with an energyabsorbing filler material 8. For example, the first and secondself-supporting wall structures 4, 6 may be assembled by firstpositioning footings 14, then securing elongated members 20 to thefootings 14 and positioning an optional retaining bracket 21 about eachelongated member 20, as shown in FIG. 3. Next, end portions of thepanels 10 may be positioned over the footings 14 and generally alignedwith respective elongated members, as shown in FIG. 4. The panels 10 maybe held in position by temporary braces (not shown) until the columns 12are assembled.

After the panels 10 are positioned, a first column face 22 may bepositioned adjacent the end portions of the panels 10, as shown in FIG.5, and a second column face 24 may be positioned adjacent the endsportions of the panels 10 opposite the first column face 22, as shown inFIG. 6. Optionally, if the first and second column faces 22, 24 arejoined together by a central portion (i.e., the first and second columnfaces are a single piece) (not shown) the first and second column faces22, 24 may be positioned simultaneously, such as by lowering the firstand second column faces 22, 24 over the elongated member 20 and footing14.

The lower ends of the first and second column faces 22, 24 may be heldagainst the panels 10 by a retaining bracket 21 or by another structure.If a retaining bracket 21 is used, the retaining bracket 21 may comprisea metal bracket that may be deformed or may be rotated, such as by ahammer, to hold the lower ends of the column faces 22, 24 firmly againstthe panels 10. A cross-piece 26 may then be positioned at the upper endof the column faces 22, 24 and, optionally, a retainer 36 may bepositioned over the cross-piece 26, as shown in FIG. 7. A first end 38of the cross-piece 26 may be coupled to the first column face 22, asecond end 40 of the cross-piece 26 may be coupled to the second columnface 24, and an intermediate portion of the cross-piece 26 may becoupled to the elongated member 20, as shown in FIG. 8. A portion of thecross-piece 26 may then be deformed, such as by rotating the bolt 32,and the cross-piece 26 and the elongated member 20 may be held intension by the footing 14, the first column face 22 and the secondcolumn face 24. The tensioned cross-piece 26 may then hold the columnfaces 22, 24 firmly against the panels 10 and apply a longitudinallyoriented compressive force to the column faces 22, 24. Upon putting thecross-piece 26 and the elongated member 20 into tension, the column 12may support the panels 10 and any temporary braces (not shown) may thenbe removed. Finally, the cap 28 may be positioned over the upper end ofthe column 12, as shown in FIG. 9.

In some embodiments, the first and second self-supporting wallstructures 4, 6 may be comprised of preformed concrete components. Thepanels 10 may be cast from concrete in a single monolithic piece or as aplurality of pieces assembled together to form the panel. For example,each panel 10 and each may be formed of two monolithic sheets, eachsheet cast in a mold, and a face of each sheet may have a finishedsurface imparted by the mold. The sheets may be assembled back to back,such the faces of the sheets, having the finished surface imparted bythe mold, may form the outer surface of the panel 10. Optionally, eachpanel 10 may also include reinforcing structures, such as one or more ofreinforcing bar (rebar), reinforcing fiber (e.g., glass fiber, steelfiber, synthetic fiber, natural fiber, polypropylene fiber, cellulosefiber, asbestos fiber, carbon fiber, etc.), and reinforcing wire thereinand may include materials, such as adhesives and filler material,therebetween. Additionally, each panel 10 may include a hollow cavitytherein. As the concrete panels 10 may be lightweight (e.g., hollow,lightweight aggregate, etc.) and may be fiber reinforced, the panels 10may prevent or reduce spalling and ricochet that may otherwise resultfrom an impact, such as by a projectile, into a conventional concretestructure.

Additionally, with reference to FIG. 9, the column faces 22, 24 may becomprised of concrete and may similarly be preformed, such as in a mold.For example, each of the column faces 22, 24 may be formed of castconcrete, which may be reinforced, such as with one or more ofreinforcing bar (rebar), reinforcing fiber (e.g., glass fiber, steelfiber, synthetic fiber, natural fiber, polypropylene fiber, cellulosefiber, asbestos fiber, carbon fiber, etc.) and reinforcing wire. In someembodiments, each of the column faces 22, 24 may not include anyexterior or exposed portions that are not formed of concrete. Eachcolumn face 22, 24 may be cast from concrete in a single monolithicpiece or as a plurality of pieces assembled together to form each columnface 22, 24, similarly to the panels 10. Optionally, each column face22, 24 may also include reinforcing structures, such as one or more ofreinforcing bar (rebar), reinforcing fiber, and reinforcing wire thereinand may include materials, such as adhesives and filler material,therebetween. Additionally, each column face 22, 24 may include a hollowcavity therein. As the concrete column faces 22, 24 may be lightweight(e.g., hollow, lightweight aggregate, etc.) and may be fiber reinforced(e.g., glass fiber, steel fiber, synthetic fiber, natural fiber,polypropylene fiber, cellulose fiber, asbestos fiber, carbon fiber,etc.), the column faces 22, 24 may prevent or reduce spalling andricochet that may otherwise result from an impact, such as by aprojectile, into a conventional concrete structure.

Although certain concrete panels and concrete column faces have beendescribed, panels and column faces formed of other materials and byother methods may also be used, as will be understood by a person ofordinary skill in the art.

In addition to assembling the first and second self-supporting wallstructures 4, 6, a permeable fence 16, such as a chain-link fence, maybe assembled at a position between the first and second self-supportingwall structures 4, 6, as shown in FIG. 2. The permeable fence 16 may besubstantially taller than the first and second self-supporting wallstructures 4, 6 and may be positioned relatively close to one of thefirst and second self-supporting wall structures 4, 6, such as within afew inches. The permeable fence 16 may be a conventional fence, such asa chain-link fence, and may be assembled according to conventionalmethods, such as by securing fence posts in concrete footings andattaching a chain-link fencing to the fence posts. Optionally, barbedwire, razor wire or another climbing deterrent 42 may be attached at ornear the top of the permeable fence 16. Additionally, the portion of thepermeable fence 16 that is encapsulated within the energy absorbingfiller material 8 may facilitate the distribution of energy loadsthrough the energy absorbing wall assembly 2. For example, a relativelylarge amount of kinetic energy, such as from a vehicle impact, may beexerted on a relatively small region of the energy absorbing wallassembly 2, such as upon a single panel 10. The permeable fence 16 maydistribute the kinetic energy from the impact among adjacent portions ofthe energy absorbing wall assembly 2, which may facilitate an efficientabsorption of the kinetic energy by the energy absorbing wall assembly 2and may also prevent a breach of the energy absorbing wall assembly 2.

After the first and second self-supporting wall structures 4, 6 areinstalled, as shown in FIG. 10, and optionally, the intermediatepermeable fence 16, as shown in FIG. 11, the energy absorbing fillermaterial 8 may be positioned between the first and secondself-supporting wall structures 4, 6. If any discrete energy absorbingstructures, such as used tires 18, are utilized, they may be positionedbetween the first and second self-supporting wall structures 4, 6, in aseries of laterally adjacent vertical stacks, as shown in FIG. 12.Optionally, a first self-supporting wall structure 4 may be assembled,structural material, such as used tires 18, may be stacked one on top ofthe other, the individual tires oriented horizontally, adjacent thefirst self-supporting wall structure 4, then the second self-supportingwall structure 6 may be assembled. Finally, a flowable energy absorbingfiller material 8 may be directed between the first and secondself-supporting wall structures 4, 6 and may substantially fill theremaining space therebetween.

If the first and second self-supporting wall structures 4, 6 include anypermeable regions where flowable energy absorbing filler material 8 mayflow through, the permeable regions may be sealed to prevent flow of theflowable energy absorbing filler material 8 therethrough.

In some embodiments, an uncured cellular concrete may be flowed betweenthe first and second wall structures 4, 6, such as by a concrete pump.After the cellular concrete is flowed into the space between the firstand second self-supporting wall structures 4, 6 the cellular concretemay become cured and provide a monolithic, rigid, cellular structure.

In additional embodiments, a flowable particulate may be directed intothe space between the first and second self-supporting wall structures4, 6. For example, a flowable particulate comprising one or more ofsand, dirt, gravel, and other flowable particulates may be directed intothe space between the first and second self-supporting wall structures4, 6.

If structural features are positioned between the first and secondself-supporting wall structures (e.g., a permeable fence 16, used tires18, etc.) the flowable energy absorbing filler material 8 (e.g., uncuredcellular concrete, flowable particulate, etc.) may be flowed around andoptionally through such structural features.

In some embodiments, the energy absorbing wall assembly 2 may berepaired after one or more energy absorption events. After one or moreenergy absorption events, such as impact with one or more projectiles,the affected regions of the first and second self-supporting wallassemblies 4, 6 may be removed. For example, columns 12 in the affectedregions may be disassembled, and affected (i.e., damaged) columns 12 andpanels 10 may be removed. After removal of the affected columns 12 andpanels 10 the underlying energy absorbing filler material 8 may berepaired. In some embodiments, a portion of damaged cellular concretemay be removed to form a cavity in a monolithic energy absorbing fillermaterial 8 and the cavity may be filled with uncured cellular concrete,which may then cure within the cavity. New columns 12 and panels 10 maythen be installed to replace the previously removed affected columns 12and panels 10. In additional embodiments, a cavity may be formed and oneor more flow paths extending from the cavity to an upper surface may beformed in the monolithic energy absorbing filler material 8 while thecolumns 12 and panels 10 are removed. Then cellular concrete may beflowed into the cavity through the one or more flow paths after the newcolumns 12 and panels 10 have been installed. Such methods may allow atime efficient and cost effective method of repair to the energyabsorbing wall assembly 2 after one or more energy absorption events.For example, an energy absorbing wall assembly 2 may be installed at asite where repeated kinetic energy events may be expected, such as ashooting range or testing facility, and the energy absorbing wallassembly 2 may be regularly and repeatedly repaired.

The energy absorbing wall assemblies 2 described herein may readilyabsorb energy, such as from impacts of vehicles or projectiles, fromshock waves, such as those resulting from explosives or industrialaccidents (e.g., at chemical plants, refineries), or from other kineticenergy sources. In view of this, the energy absorbing wall assemblies 2described herein may be utilized in a number of applications whereenergy absorption may be beneficial. In some embodiments, an energyabsorbing wall assembly 2 may be utilized as a security wall. As asecurity wall an energy absorbing wall assembly 2 may provide protectionby providing a barrier that may be difficult to penetrate or climb over.The energy absorbing wall assembly 2 may absorb a shock wave andresulting shrapnel directed toward the wall from an explosive detonatingnear the energy absorbing wall assembly 2. Additionally, the energyabsorbing wall assembly 2 may absorb the impact of a vehicleintentionally rammed into the energy absorbing wall assembly 2, mayabsorb the energy of projectiles, such as bullets, and otherwise preventpenetration of the energy absorbing wall assembly 2 by potentiallyharmful kinetic energy into a protected area behind the energy absorbingwall assembly 2. In additional embodiments, energy absorbing wallassemblies 2 may be utilized in other applications, such as nearroadways to absorb the impact of an automobile veering off of theroadway, or as an exterior wall of a building among other possibleapplications.

While the present invention has been described herein with respect tocertain embodiments, those of ordinary skill in the art will recognizeand appreciate that it is not so limited. Rather, many additions,deletions and modifications to the embodiments described herein may bemade without departing from the scope of the invention as hereinafterclaimed. In addition, features from one embodiment may be combined withfeatures of another embodiment while still being encompassed within thescope of the invention as contemplated by the inventor.

1. An energy absorbing wall assembly, comprising: a firstself-supporting wall structure; a second self-supporting wall structure;and an energy absorbing filler material positioned between the firstself-supporting wall structure and the second self-supporting wallstructure.
 2. The energy absorbing wall assembly of claim 1, wherein:the energy absorbing filler material comprises a collapsible material.3. The energy absorbing wall assembly of claim 2, wherein: thecollapsible material comprises cellular concrete.
 4. The energyabsorbing wall assembly of claim 1, wherein: the energy absorbing fillermaterial comprises a flowable particulate.
 5. The energy absorbing wallassembly of claim 4, wherein: the flowable particulate comprises atleast one of sand, dirt and gravel.
 6. The energy absorbing wallassembly of claim 1, wherein the first self-supporting wall structurecomprises a first column and panel fence.
 7. The energy absorbing wallassembly of claim 6, wherein the second self-supporting wall structurecomprises a second column and panel fence.
 8. The energy absorbing wallassembly of claim 7, wherein the columns of the first column and panelfence and the second column and panel fence comprise: an elongatedmember having a first end secured to a footing and a second end; a firstcolumn face and an opposing second column face forming at least onechannel therebetween sized and configured to receive an end portion ofat least one fence panel; and a cross-piece having a first end coupledto the first column face, a second end coupled to the second column faceand an intermediate portion coupled to the second end of the elongatedmember, the cross-piece and the elongated member being placed in tensionby the footing, the first column face and the second column face atleast when an end portion of at least one fence panel is positioned inthe at least one channel.
 9. The energy absorbing wall assembly of claim1, wherein the second self-supporting wall structure is positionedsubstantially parallel to the first self-supporting wall structure. 10.The energy absorbing wall assembly of claim 1, further comprising apermeable fence positioned between the first self-supporting wallstructure and the second self-supporting wall structure.
 11. The energyabsorbing wall assembly of claim 10, wherein the permeable fence extendsabove the first self-supporting wall structure and the secondself-supporting wall structure.
 12. The energy absorbing wall assemblyof claim 11, wherein a lower portion of the permeable fence issurrounded by the energy absorbing filler material.
 13. The energyabsorbing wall assembly of claim 12, wherein the permeable fencecomprises a chain-link fence.
 14. The energy absorbing wall assembly ofclaim 1, wherein the filler material further comprises discrete energyabsorbing structures positioned between the first self-supporting wallstructure and the second self-supporting wall structure.
 15. The energyabsorbing wall assembly of claim 14, wherein the discrete energyabsorbing structures comprise used tires.
 16. The energy absorbing wallassembly of claim 1, wherein at least one of the first self-supportingwall structure and the second self-supporting wall structure have theappearance of a conventional fence.
 17. A method of making an energyabsorbing wall assembly, the method comprising: assembling a firstself-supporting wall structure; assembling a second self-supporting wallstructure defining a space between the first self-supporting wallstructure and the second self-supporting wall structure; and flowing afiller material into the space between the first self-supporting wallstructure and the second self-supporting wall structure.
 18. The methodof claim 17, wherein flowing a filler material into the space betweenthe first self-supporting wall structure and the second self-supportingwall structure comprises flowing an uncured cellular concrete into thespace between the first self-supporting wall structure and the secondself-supporting wall structure.
 19. The method of claim 17, whereinflowing a filler material into the space between the firstself-supporting wall structure and the second self-supporting wallstructure comprises flowing a particulate into the space between thefirst self-supporting wall structure and the second self-supporting wallstructure.
 20. The method of claim 17, further comprising assembling apermeable fence between the first self-supporting wall structure and thesecond self-supporting wall structure.
 21. The method of claim 20,further comprising flowing the filler material through at least aportion of the permeable fence.
 22. The method of claim 17, furthercomprising positioning discrete energy absorbing structures between thefirst self-supporting wall structure and the second self-supporting wallstructure.
 23. The method of claim 22, further comprising flowing thefiller material around the discrete energy absorbing structures.